Foam with a density of 18 lb/ft3 was used to make the core of the wheel. A SolidWorks model was made from our given outer rim profile dimensions, hub dimensions, and strength calculations for the sidewalls. Iterations were also done to reduce weight but maintain strength. Using the Louisiana Tech architecture department’s CNC router, the foam was cut by importing our SolidWorks file into the router’s computer. Due to the router’s z-axis limitations, we had to cut the foam block in half before actually putting it in the router. For each half one side was cut, then the block was flipped and the other side cut. Figure 7.4 illustrates a part of the foam cutting process using above mentioned CNC router.
